CAG 9000 QUALITY REQIRMENTS FOR SUPPLIERS TYPE 12 & 13. REVISION NO. : 9 DATE : 21.6.06 APPROVED BY : B. FRUMKES - QM -DIRECTOR Doc. No.: CAG 9000 Page 1 of 12 Pages
CONTENTS AND PARAGRAPH INDEX PARAGRAPH SUBJECT 1. Definitions 2. Introduction 3. Approval Procedure 3.1 Approval of Subcontractors/ Suppliers 3.2 Certification 3.3 Supplier Control of Lower-Tier Suppliers 4. Quality System Requirements 4.1 Responsibility and Authority 4.2 Quality Management System 4.3 Contract Review 4.4 Document and Data Control 4.5 Purchasing 4.6 Control of Customer Supplied Product 4.7 Inspection and Testing 4.8 Inspection and Test Status 4.9 Control of Nonconforming Product 4.10 Corrective and Preventive Action 4.11 Handling, Storage, Packaging, Preservation and Delivery 4.12 Control Of Quality Records 4.13 Statistical Techniques 5 Ref. Documents. Doc. No.: CAG 9000 Page 2 of 12 Pages
1. DEFINITIONS Supplier A company providing goods (products, services, tools, etc.) to the Commercial Aircraft Group at Israel Aircraft Industries, Ltd. CAAI Civil Aviation Administration - of Israel Ministry of Transport. IAI-CAG Israel Aircraft Industries/Commercial Aircraft Group. IAI INTERNET SITE Internet site http://www.iai.co.il/suppliers-eng for: approved suppliers list, process specification list, CAG9000 document, products code, drawings list and additional information for suppliers. AS9100 "International Aerospace Quality Standard". This standard can be obtained from www.sae.org/servlets/search by typing AS9100 into the search window. SUPPLIER TYPE Supplier Type 12 - A supplier (of parts or assemblies Built-To-Print type) that meets the criteria of CAG (Commercial Aircraft Group) specification CAG 9000 requirements, except for Design Control and Quality cost paragraphs. Supplier Type 13 - A supplier (of parts or assemblies Built-To-Spec type) that meets the criteria of the Commercial Aircraft Group requirements, CAG9000. Supplier Type 14 A manufacturer of Shelf Items (stock components s.a. material or fasteners) per international or IAI-CAG approved standards. Supplier Type 1D A type 14 manufacturer which passed successfully an IAI- CAG technical survey. Note : Suppliers type 12 & 13 who are purchasing Shelf Items from type 1D suppliers, shall conduct each year at least one laboratory testing in an IAI laboratory, to a lot received from each supplier. Supplier type 1E A supplier of Shelf Items (normally distributor type) contracted by IAI-CAG to supply Shelf Items directly to the manufacturing departments or to the Assembly Lines. The supplier is responsible for all receiving inspection tasks (including laboratory testing). Vendor manager-logistics authority. who uses as a liaison between CAG and the supplier. Doc. No.: CAG 9000 Page 3 of 12 Pages
2. INTRODUCTION All IAI-CAG suppliers must comply with the requirements defined at AS9100 and the additional requirements defined in this document. This document defines the procedures for obtaining and maintaining IAI-CAG approval and specifies the requirements for an acceptable quality system and adequate product / process controls. 3. APPROVAL PROCEDURE 3.1. Approval of suppliers. Demonstration of compliance with the quality system requirements defined in this document and a demonstrated capability to meet the product/process control and technical requirements for the intended scope of work are initial conditions to IAI-CAG s approval. Request for Clarifications shall be addressed to : Director, Quality Management Commercial Aircraft Group, Dpt. 4090. Israel Aircraft Industries Ltd. Ben Gurion International Airport. 70100 Surveys for approval will be performed by IAI-CAG auditors per this document and the relevant IAI-CAG procedures, indicated in this document. 3.1.1 Certification for Special Processes: Supplier type 12 who performs special processes according to IAI process specifications, shall be certified by IAI CAG for each special process. Whenever a supplier (type 12) or his sub tier is required to perform any of the processes listed below, these processes must be performed by an IAI-CAG certified and approved supplier whose name and address can be found in IAI's approved suppliers list. - Chemical milling - Heat treatment - Surface treatment and plating - Welding, brazing, soldering - Laminated structures - Structural adhesive bonding - Hot Forming - Thread Rolling - Shot Penning and Forming - Nondestructive testing Doc. No.: CAG 9000 Page 4 of 12 Pages
- Hot dimpling - Casting A request for a special process approval will be submitted by the supplier to the vendor manager in IAI Logistic. Accomplishment of special processes in accordance to IAI's Customer's Process Specifications must be performed at approved suppliers as defined in the contract between IAI -CAG and its Customer. 3.2. Certification When the supplier will be approved, the supplier will be added into the IAI internet site http://www.iai.co.il/suppliers-eng The CAG Suppliers Manager must be notified immediately in writing by the supplier if any orders are received from IAI-CAG which are outside the scope of the approval presently granted to the supplier. IAI-CAG reserves the right to withdraw the supplier s authorization, wholly or in part at any time. Continued authorization is dependent upon evidence of continued demonstration of compliance with these requirements and satisfactory product quality performance. The supplier performance will be rated by the IAI-CAG - supplier rating system. Periodic survey of the supplier s (and/or his lower-tier) quality system, product and/or process will be accomplished by IAI-CAG. A supplier of IAI CAG, in Israel only, may be subject to occasional or permanent surveys by CAAI, according to CAAI decision. IAI-CAG & CAAI representatives has the right of entry and inspection at the suppliers and his lower tier suppliers production site. 3.3. Supplier Control Of Lower-Tier Suppliers 3.3.1 The supplier shall be responsible for the quality approval of its lower-tier suppliers, by means of control and appropriate surveys. 3.3.2 The supplier shall provide IAI-CAG, upon request, with information regarding delegation of authority granted to his lower-tier suppliers, to inspect parts or assemblies for which the supplier is responsible. 3.3.3 The supplier shall provide, if so requested, IAI-CAG with data regarding his lower-tier suppliers that are involved in performing of IAI-CAG Special Process. 3.3.4 The supplier shall take actions and initiate applications in order to receive a TSO/PMA certificate for his products, in order to supply them with an airworthiness-tag, 8130-3 or equivalent. Doc. No.: CAG 9000 Page 5 of 12 Pages
4. 4 QUALITY SYSTEM REQUIREMENTS 4.1 Responsibility and Authority The supplier s quality system shall comply with AS9100 and the additional requirements defined in this document. Upon request of IAI-CAG, the supplier will provide reports of quality system status and failure analysis. Note :In all places where : AS9100 states The requirements of this document, the implication is to AS9100 plus additional requirements of CAG 9000. Quality Management Manager of the supplier will act as a focal point for the IAI- CAG - Quality Management authorities and the vendors manager. The supplier shall promptly notify IAI- CAG of any changes to the Quality Management system, replacement of key management personnel, organization structure change in facility location and any other significant changes that affects quality system. None of these changes will affect the quality of goods supplied, or delivery time to IAI-CAG. 4.1.1 Management Review: The supplier s management review will be carried out at least once a year. 4.2 Quality Management System 4.2.1 Quality Planning: The supplier shall prepare a quality plan (QP) in accordance with the requirements specified in this document. Upon which the quality of goods sent to IAI shall be managed. The QP shall include a matrix show compliance with this document. The QP shall be submitted to IAI-CAG for approval, upon request. 4.2.2 The supplier shall prepare a FOD (Foreign Object Damage) and I&R (Interchangeability & Replaceability) Plan upon CAG requirement. 4.2.3 Translation to English: The Suppliers shall maintain an English language translation of: (A) Quality system procedures (B) Quality plan (C) Any other document required by IAI-CAG. The above mentioned documents will be submitted to IAI-CAG for approval. 4.2.4 Configuration Management: Doc. No.: CAG 9000 Page 6 of 12 Pages
Suppliers of serialized aircraft assemblies under the definition of an Outside Production Planning Specification (OPPS) must conform to the additional requirements defined in IAI CAG production Division Procedure NO.214.42.39 Supplier/Sub contractor Configuration management requirements, and ISO 10007 procedure. 4.3 Contract Review Contract reviews shall insure that supplier is working in accordance to the products code and document revisions listed in the IAI internet site. 4.4 Document And Data Control Suppliers receiving Engineering definition data in digital format must conform to the additional requirements in IAI CAG Quality Management Procedure NO. 342.40.07 Quality Assurance Standard for Digital Product Definition (DPD) at IAI CAG suppliers (latest version). The process at the supplier must be authorized by IAI CAG. 4.5 Purchasing (for type 12 suppliers) 4.5.1 Materials, supplies processes and services not provided by IAI-CAG, must be obtained only from IAI-CAG approved or agreed sources with the prior approval of IAI-CAG. 4.5.2 The supplier shall indicate on his purchase orders to sub contractors that the goods are for IAI-CAG projects. 4.5.3 Hardware/Raw material: These are the quality requirements that the sub contractors of CAG must include in their orders to framework agreement suppliers: 1. The hardware/raw material in this P.O. is designated for IAI products. 2. The quality assurance plan between IAI and the supplier (1E) applies to this P.O. 3. The hardware/raw material in this P.O shall be inspected and tested by the supplier (1E) in accordance with the Quality Assurance plan. 4. Each shipment must be accompanied with COC shipper containing a certificate stating the following: This lot is from an IAI approved manufacturer, was lab tested (if required) and meets CPK>1.33 (for hardware only ) as per the Quality Assurance Plan. The parts were dimensionally inspected and the Certificate of Test was compared against the procurement specification (if required). The original COC and COT from the manufacturer are retained in the supplier files. Parts meet the requirements of the Quality assurance plan. Doc. No.: CAG 9000 Page 7 of 12 Pages
The A/M certificate (COC shipper) shall be signed by the supplier s (1E) inspector and the IAI delegate inspector at the supplier s site. 4.6 Control Of Customer Supplied Product 4.6.1 Materials and supplies provided by IAI-CAG shall be used only in fulfillment of the contract/order for which they were supplied. 4.6.2 All jigs and tools provided by IAI-CAG, and used in manufacturing, shall be inspected by the supplier prior to use for completeness, freedom from damage and evidence of inspection (the tools and jigs will be marked as "IAI-CAG property"). The supplier shall establish procedures to register, assure safe storage and periodically recertify all jigs and tools, including those manufactured by the supplier in support of work carried out. 4.6.3 All tooling serving as inspection media shall be inspected initially and then periodically not exceeding an interval of 24 months. The supplier will maintain a list of all tools and jigs that are subject to a periodical inspection. 4.6.4 The supplier shall not modify / amend CAG's supplied products without CAG's approval. 4.7 Inspection And Testing Supplement for type 12 suppliers: 4.7.1 in case the purchase is not made from a frame work agreement supplier: Frequency and sampling plan for incoming laboratory testing will be per PS850110 (Fasteners), PS850100 (Raw material). 4.7.2 The supplier shall ensure that parts or assemblies incorporating interchangeability features are produced strictly to applicable dimensional, jig or gauge standards. The supplier may be called upon to demonstrate interchangeability aspects as required by the Quality Manager of the ordering site. 4.7.3 In production of critical parts the following process specification need to be implemented: PS90.1500 and PS90.1501. 4.7.4 All products shall be inspected to verify conformity to specified requirements (100% inspection). Sampling inspection may be used as a means of product inspection if so approved by IAI-CAG Quality Management Director. 4.7.5 The supplier shall prepare a FAI Plan, in accordance with the requirements of AS9102 standard. The FAI plan shall be presented if so requested by IAI. Doc. No.: CAG 9000 Page 8 of 12 Pages
The forthcoming paragraphs are for type 12 and type 13 suppliers: 4.7.6 The supplier shall coordinate the phase of inspection and/or test of product characteristic, with IAI-CAG representatives. When requested, the supplier shall provide all necessary planning papers for IAI- CAG review and approval for identification of IAI-CAG inspection points. 4.7.7 The performance or witnessing of Source Inspection and test by IAI-CAG personnel and CAAI personnel and conformance to the requirements of this document, shall not relieve the supplier of his responsibility for furnishing specified supplies and services which meet all purchase document requirements. Additionally, such source inspection does not guarantee acceptance of the product at the destination or in any way restrict IAI-CAG s right to reject nonconforming products delivered to IAI-CAG facilities or other designated sites due to latent defects. IAI-CAG reserves the right to perform receiving inspection at the supplier s plant and final inspection at IAI-CAG. 4.7.8 The supplier shall not conduct any additional work on any product which has been accepted and bought off by IAI-CAG Quality Management representative, unless authorized in writing by IAI-CAG QM. 4.8 Inspection And Test Status Supplement for type 12 supplier: 4.8.1 The supplier shall issue a stamps procedure; which will be reviewed during his approval. 4.8.2 Quality inspectors shall be subject to periodic visual acuity test in conjunction with QMP 362.40.04. 4.9 Control Of Non Conforming Product Supplement for type 12 supplier: 4.9.1 A supplier of the IAI-CAG is not authorized to handle a nonconforming product by his own MRB system, unless granted with an IAI-CAG letter of approval for such purpose. 4.9.2 A supplier whose MRB system is not authorized by IAI-CAG shall report all applicable non-conformities to IAI-CAG using IAI-CAG Material Review form. (see appendix). In case the nonconformance reoccurs, a new MRB shall be submitted. 4.10 Corrective And Preventive Action 4.10.1 In the case of Items which have been rejected on a U/R and returned to the supplier for repair and the discrepancy was not confirmed by the supplier, IAI- CAG Q/M approval is required before shipping these items back to IAI-CAG. Doc. No.: CAG 9000 Page 9 of 12 Pages
4.11 Shipping Documents: The supplier shall furnish each final product with the following shipping documents attached (in English) : 1. Certificate of Conformity (CoC). 2. Airworthiness tag - JAA form one or FAA form 8130-3 or serviceability tag from the local authority for suppliers with PMA. 3 Serviceability tag of the supplier for suppliers without PMA. 4. If necessary, FAI reports for first article inspected. 5. Weighing record list. 6. C.O.T from forging supplier. 7. ATP from type 13 supplier. 8. For assembly supplier also: 8.1 I/R (Interchangeability/Replaceability) test result (if relevant). 8.2 Incomplete Task Log (ITL) - review and approved by IAI (if relevant). 8.3 If necessary, loose parts list. 8.4 If necessary,list of fatigue critical parts (FCI) with P/N and S/N. 8.5. A list of MRB s from a type 12 supplier, and from a type 13 supplier which has deviated from a FFF approved by CAG. 8.6 A statement on the status of configuration control from a type 12 supplier. 8.7 Serviceability tag of CAG from a supplier with a written inspection approval authorization from the CAG. 4.12 Control Of Quality Records: Supplement: Quality records shall be kept for 7 years. CAG shall be informed prior to disposal. 4.13 Statistical Techniques 4.13.1 The supplier shall conduct Statistical Process Control according to AS 9103 - "Variation Management of Key Characteristics. 4.13.2 The key characteristics (Kc) will be determined by the CAG, in addition the supplier shall maintain a Program in order to identify and determine Kc s in its processes, performed for IAI-CAG. 5. REF. DOCUMENTS 1 IAI-CAG QMP. No. 362.40.04 Visual acuity test. 2 IAI-CAG QMP. No. 342.40.07 Quality assurance standard for digital product definition (DPD) at IAI CAG suppliers 3 IAI- CAG Production Div. Procedure No. 214.42.39 - "Supplier/subcontractor configuration management requirements". 4 PS90.1500- Identification, marking, handling, process. & insp. of critical parts. 5 PS90.1501- Traceability procedure for critical parts, Engineering requirements. 6 PS85.0100- Incoming raw material acceptance testing (Laboratory testing). 7 PS85.0110- Acceptance of incoming fasteners. Doc. No.: CAG 9000 Page 10 of 12 Pages
Note: All of the above mentioned documents can be viewed at IAI s suppliers site www.iai.co.il/suppliers-eng after identification at my site. 8 AS9103 - "Variation management of key characteristics". 9 AS9102-FAI-Aerospace first article inspection requirements. 10 ISO 10007-QM systems - Guidelines for configurations management. 11 AS 9100 International aerospace quality standard. Doc. No.: CAG 9000 Page 11 of 12 Pages
APPENDIX - MRB FORM MATERIAL REVIEW (MR) PAGE OF MR No. (Supplier) Work Order/P.O. Oper No. QTY Ordered MR QTY Accept Rework Scrap Dept. MR No.(IAI) PART NO. PART NAME DRAWING NO. ISSUE QTY/AC PROJECT MANUFACTURER/ SUPPLIER SERIAL NO. / BATCH NO. PART DESCRIPTION (PART FUNCTION, NEXT ASSY). DETAILED DESCRIPTION OF DISCREPANCY -- - - - - INSPECTOR SIGNATURE PRODUCTION MANAGER SIGNATURE DATE BOARD DECISIONS (DISPOSITION & REPAIR METHOD). ACCEPT REPAIR METHOD : REPAIR *CLASS I CLASS II CAUSE : MRB CLASSIFICATION CORRECTIVE ACTION : CAUSE CODE QUALITY ASSURANCE PRODUCTION ENG. ENGINEERING CUSTOMER REP. *CAAI DATE NAME SIGNATURE REPAIR, ACCEPTANCE OR REJECTION CLEARANCE. DISC. CODE ---------------------- ------------------------------------------ ------------------------------- DATE INSPECTOR SIGNATURE CORRECTIVE ACTION TAKEN ---------------------- ------------------------------------------ ------------------------------- * CAAI APPROVAL FOR MRB CLASS I DATE QUALITY ASSURANCE SIGNATURE Doc. No.: CAG 9000 Page 12 of 12 Pages